Systems and methods for pipeline device propulsion

ABSTRACT

A method for sealing a leak in a pipeline used to transport fluid includes positioning a sealing device within the pipeline, moving the sealing device through the pipeline to a leak location, and internally generating an inflation pressure to inflate the sealing device to substantially cover a leak opening and limit release of the fluid from the pipeline.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

The present application is a continuation of U.S. application Ser. No.14/533,707, filed Nov. 5, 2014, which is a continuation-in-part of U.S.application Ser. No. 13/955,929, filed Jul. 31, 2013. Both applicationsare incorporated herein by reference in their entirety.

BACKGROUND

Pipelines are used to transport fuels and other fluid goods between oneor more locations. For instance, pipeline transport is often the mosteconomical way to transport large quantities of oil or natural gas overland. A pipeline for transporting fluid goods is constructed to resistruptures or leaks within the pipeline. However, the pipeline may developa leak or rupture through which the fluid goods may escape, resulting ina loss of goods and potentially causing further damage to the pipelineif the rupture or leak is not patched or sealed within a reasonabletime.

A fluid pipeline may include block valves or block valve stationspositioned at intervals (e.g., every 20 to 30 miles) along the pipeline.When a leak is identified within the pipeline, these block valves may beclosed to isolate the leak to a particular segment between two blockvalves. However, the fluid goods within this particular segment, whichmay be a stretch of pipeline over a long distance, may be lost throughthe leak before the leak can be patched or sealed. Also, the closedblock valves may prevent fluid from being transported through thepipeline until the leak is sealed, perhaps blocking the supply of thefluid goods to one or more locations for a prolonged period of time.

SUMMARY

An embodiment of the present disclosure relates to a method for sealinga leak in a pipeline used to transport fluid. The method includespositioning a sealing device within the pipeline, moving the sealingdevice through the pipeline to a leak location, and internallygenerating an inflation pressure to inflate the sealing device tosubstantially cover a leak opening and limit release of the fluid fromthe pipeline.

Another embodiment of the present disclosure relates to a sealing devicefor sealing a leak within a pipeline for transporting fluid. The sealingdevice includes a frame, and an inflatable bag coupled to the frame andsized according to one or more dimensions of the pipeline. The frame andthe inflatable bag are configured to move through the pipeline. Theinflatable bag comprises a gas generator and is configured to at leastpartially seal the leak and to inhibit release of the fluid from thepipeline when the inflatable bag is inflated.

Another embodiment of the present disclosure relates to a sealing devicefor sealing a leak within a pipeline for transporting fluid. The sealingdevice includes a closed flexible wall formed into a substantiallytubular shape defining an opening, and an internal frame coupled to theclosed flexible wall and configured to control a movement of the closedflexible wall by applying a force to the closed flexible wall. Themovement of the closed flexible wall moves the sealing device throughthe pipeline, and the sealing device may be deployed in order to sealthe leak.

Another embodiment of the present disclosure relates to a system forsealing a leak within a pipeline for transporting fluid. The systemincludes a sealing device, which includes a flexible wall formed into asubstantially tubular shape defining an opening, and an internal framecoupled to the flexible wall and configured to control a movement of theflexible wall by applying a force to the flexible wall. The movement ofthe flexible wall moves the sealing device through the pipeline, and thesealing device may be deployed in order to seal the leak. The systemalso includes a sensor assembly configured to monitor a pipelinecondition, and a control module configured to receive a signal from thesensor assembly, and to control the force applied by the internal frame.

Another embodiment relates to a method for sealing a leak in a pipelineused to transport fluid, including positioning a sealing device withinthe pipeline; directing a portion of the fluid in the pipeline to apropulsion device coupled to the sealing device; and moving the sealingdevice through the pipeline by combusting the fluid with an oxidizerwithin the propulsion device.

Another embodiment relates to a sealing device for sealing a leak withina pipeline for transporting fluid, including a frame; an inflatable bagcoupled to the frame; and an engine configured to use the fluid withinthe pipeline as fuel to propel the frame and inflatable bag through thepipeline.

Another embodiment relates to a pipeline device configured to travelwithin a pipeline, including a housing; a propulsion system disposed atleast partially within the housing and configured to combust a fuel andan oxidizer; an oxidizer source configured to provide the oxidizer tothe propulsion system; and a fuel source configured to direct fueltravelling within the pipeline to the propulsion system.

Another embodiment relates to a method of moving a pipeline devicethrough a pipeline, including positioning a pipeline device within apipeline, the pipeline device including a propulsion device; andpropelling the pipeline device through the pipeline using the propulsiondevice by directing a portion of a fuel traveling through the pipelineto a combustion chamber of the propulsion device; and directing anoxidizer from an oxidizer source to the combustion chamber; andcombusting the fuel with the oxidizer within the combustion chamber.

Another embodiment relates to a method of moving a pipeline devicethrough a pipeline, including directing a portion of a fuel travelingthrough a pipeline to a combustion engine of a pipeline device;directing an oxidizer from an oxidizer source to the combustion engine;and combusting the fuel with the oxidizer within the combustion engineto propel the pipeline device through the pipeline in an airbornemanner.

The foregoing summary is illustrative only and is not intended to be inany way limiting. In addition to the illustrative aspects, embodiments,and features described above, further aspects, embodiments, and featureswill become apparent by reference to the drawings and the followingdetailed description.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a side view of a fluid pipeline according to one embodiment.

FIG. 2 is a perspective view of a sealing device for the leak sealingsystem in an uninflated state within the fluid pipeline according to oneembodiment.

FIG. 3 is a perspective view of the sealing device of FIG. 2 in aninflated state within the fluid pipeline according to one embodiment.

FIG. 4 is a schematic view of a sealing device and a pipeline inspectiongauge within the fluid pipeline according to one embodiment.

FIG. 5 is a perspective view of a sealing device for the leak sealingsystem according to one embodiment.

FIG. 6 is a side plan view of the sealing device of FIG. 5 according toone embodiment.

FIG. 7 is a block diagram of a control module for a sealing deviceaccording to one embodiment.

FIG. 8 is a flow chart of a method for identifying a leak within thepipeline.

FIG. 9 is a schematic illustration of a pipeline device travellingwithin a pipeline according to another embodiment.

FIG. 10 is a schematic illustration of the pipeline device of FIG. 9according to one embodiment.

FIG. 11 is a schematic block diagram of a propulsion system of thepipeline device of FIG. 9 according to one embodiment.

FIG. 12 is a block diagram of a control system usable with the pipelinedevice of FIG. 9 according to one embodiment.

FIG. 13 is a method of using a pipeline device within a pipelineaccording to one embodiment.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying drawings, which form a part hereof. In the drawings,similar symbols typically identify similar components, unless contextdictates otherwise. The illustrative embodiments described in thedetailed description, drawings, and claims are not meant to be limiting.Other embodiments may be utilized, and other changes may be made,without departing from the spirit or scope of the subject matterpresented here.

Referring generally to the figures, a leak sealing system is shown forsealing a leak within a fluid pipeline. The leak sealing system includesa sealing device configured to move to a leak location within thepipeline, deploying or inflating to seal a leak within the pipeline. Thesealing device is sized and shaped such that fluid is able to flow pastor through the sealing device when the sealing device is inflated,maintaining the transportation of fluid through the pipeline. The leaksealing system also includes a sensor assembly configured to monitorconditions of the pipeline in order to determine the location of theleak and the location of the sealing device as it moves through thepipeline. The sealing device may be sized and shaped to fit the pipelinein order to provide a fluid seal, inhibiting the release of fluid fromthe leak until the leak can be more permanently patched or repaired.

Referring to FIG. 1, pipeline 10 for transporting goods is shownaccording to one embodiment. In this embodiment, pipeline 10 is elevatedabove the ground, but pipeline 10 may otherwise be positioned below orwithin the ground, or in any other arrangement as may be suitable forthe particular application of pipeline 10. In some embodiments, pipeline10 is used to transport fluid (e.g., gas, liquid, etc.) between twopoints. For instance, pipeline 10 may be used to transport fuel, such asnatural gas, between two or more sites (e.g., fuel refinery, fuelstorage area, fueling station, etc.) as part of a fuel transportationsystem. In other embodiments, pipeline 10 may be used to transportsewage, slurry, water, or any other fluid.

In the embodiment of FIG. 1, pipeline 10 includes block valves 12positioned at intervals along pipeline 10. The distance between blockvalves 12 may vary depending upon the length of pipeline 10 and otherengineering considerations, but in various other embodiments thedistance may range from a few meters to many kilometers. Block valves 12are configured to selectively block fluid flow in one or both directionsin order to isolate a segment of pipeline 10 for maintenance or repair.In the event of a leak within a particular section or segment ofpipeline 10, block valves 12 may be closed (e.g., actuated) to block theflow of fluid through the particular section or segment of pipeline 10containing the leak. When block valves 12 are closed, the flow of fluidthrough pipeline 10 is halted, perhaps shorting or reducing a fuelsupply to one or more fuel sites until the leak can be fixed or patched.The fluid within the particular segment having the leak (i.e., betweenblock valves 12 surrounding the leak) may exit pipeline 10 through theleak.

In an exemplary embodiment, block valves 12 (e.g., block valve stations)include flow sensors 14 (i.e., fluid sensors, fluid flow sensors, flowvelocity sensors, etc.) configured to monitor the flow of fluid throughpipeline 10. Flow sensors 14 may be configured to monitor a flowvelocity of the fluid at a specific location within pipeline 10 (e.g.,at block valve 12, etc.), a volumetric flow rate of the fluid at aspecific point or location within pipeline 10, and/or another measure offluid flow suitable for the particular application of flow sensors 14and/or the leak sealing system. In one embodiment, flow sensors 14 areincluded as part of sensor assembly 26, which is described in furtherdetail below and shown in FIG. 2.

Flow sensors 14 may be used to detect and/or locate a leak withinpipeline 10 by detecting a reduced fluid flow (e.g., flow velocity,volumetric flow rate, etc.) at a particular location, which may indicatea loss of fluid through a leak in pipeline 10. In one embodiment, flowsensors 14 are configured to determine the location of the leak (i.e.,the leak location) based on the fluid flow within pipeline 10. In thisembodiment, flow sensors 14 are configured to send one or more signalsrepresenting the leak location to control module 50 (shown in FIG. 2).In another embodiment, flow sensors 14 are configured to send one ormore signals representing the fluid flow within pipeline 10 to controlmodule 50 (e.g., controller), and control module 50 is configured (e.g.,programmed) to determine the leak location based on the signals receivedfrom flow sensors 14.

While flow sensors 14 are positioned at block valves 12 in theillustrated embodiment of FIG. 1, flow sensors 14 may be otherwisepositioned within pipeline 10 in other embodiments. For instance, flowsensors 14 may be positioned on interior wall 16 (shown in FIG. 2) ofpipeline 10, coupled to sealing device 20 (shown in FIG. 2) or sealingdevice 60 (shown in FIGS. 5 and 6) as part of sensor assembly 26, orpositioned in another location suitable for monitoring a fluid flowwithin pipeline 10. Pipeline 10 may include a plurality of flow sensors14 as may be suitable for the particular application of flow sensors 14and/or the leak sealing system, and flow sensors 14 may be positioned atmore frequent intervals along pipeline 10 than the frequency of blockvalves 12 (i.e., there may be less distance between each flow sensor 14within pipeline 10 than the distance between each block valve 12 alongpipeline 10).

Referring now to FIGS. 2 and 3, sealing device 20 is shown withinpipeline 10 according to one embodiment. In this embodiment, sealingdevice 20 (e.g., inflatable device, airbag device, airbag, etc.) isconfigured to move through pipeline 10 in an uninflated state (i.e.,uninflated or non-inflated configuration or arrangement) (as shown inFIG. 2), inflating to an inflated state to seal a leak such as leak 18(i.e., leak opening) on interior wall 16 of pipeline 10 (as shown inFIG. 3). In other embodiments, sealing device 20 may be otherwisedeployed in order to substantially cover a leak and limit the release offluid from pipeline 10. Sealing device 20 and the leak sealing systemmay be used for natural gas pipelines, or for pipelines carrying otherfluids, such as water, oil, or any other fluid transported through apipeline. In one embodiment, sealing device 20 is configured to movealong with the fluid flow through pipeline 10, being pushed or guided bythe force of the fluid through pipeline 10. In other embodiments,sealing device 20 is moved or guided through pipeline 10 by one or moreexternal forces. For instance, sealing device 20 may be configured suchthat one or more components of sealing device 20 are subject to remotecontrol. In this embodiment, an operator or technician may be able toremotely control one or more components of sealing device 20 in order toguide sealing device 20 through pipeline 10. For instance, in oneembodiment, sealing device 20 includes a guide (e.g., rudder, fin, flag,etc.) (not shown) configured to steer or move sealing device 20 throughpipeline 10. In this embodiment, the guide may be remotely controlled byan operator to move sealing device 20 through pipeline 10, or the guidemay be pushed or forced by the flow of fluid within pipeline 10 to movesealing device 20 through pipeline 10. The guide is configured toreceive a force from the fluid within pipeline 10 in order to movesealing device 20 through pipeline 10. In another embodiment, sealingdevice 20 is coupled to pipeline inspection gauge (PIG) 30 (shown inFIG. 4), and is moved or guided through pipeline 10 by PIG 30. PIG 30may be remotely controlled by an operator or configured to automaticallymove through pipeline 10 to find leak 18. In other embodiments, sealingdevice 20 is self-propelled, having one or more components configured topush, move, and/or guide sealing device 20 through pipeline 10. In stillother embodiments, sealing device 20 may be configured to move throughpipeline 10 in another manner suitable for the particular application ofsealing device 20 or for the conditions of pipeline 10.

Sealing device 20 is intended to prevent or limit the loss (i.e.,release) of fluid from pipeline 10 through leak 18 by deploying (e.g.,inflating) to cover leak 18 (as shown in FIG. 3). In one embodiment,sealing device 20 has an outer diameter approximately equal to an innerdiameter of pipeline 10 (e.g., an inner diameter of interior wall 16)when sealing device 20 is inflated, so that sealing device 20 provides afluid seal against interior wall 16. Sealing device 20 is configured toinflate in response to an inflation pressure. In one embodiment, theinflation pressure is internally generated or provided by one or morecomponents of sealing device 20, such as a pyrotechnic reaction createdwithin bag 22 of sealing device 20. In another embodiment, the inflationpressure is internally generated by an external force or componentinteracting with sealing device 20, such as a chemical reaction with thefluid within pipeline 10. For instance, sealing device 20 may include orbe made from an oxidizer (e.g., oxidizing agent) configured to reactwith a gaseous fuel present within pipeline 10. The oxidizer may beexposed to the gaseous fuel as necessary or desired in order to create achemical reaction sufficient to generate or provide the inflationpressure required to inflate sealing device 20. In another embodiment,bag 22 includes a gas generator and the inflation pressure is producedby the gas generator. In other embodiments, the inflation pressure maybe internally generated or provided by another source suitable forgenerating or providing an inflation pressure sufficient to inflatesealing device 20.

Sealing device 20 also includes actuator 34 (e.g., deployment device orinflation actuator). Actuator 34 is configured to be actuated ortriggered, causing an inflation pressure sufficient to inflate sealingdevice 20 to be generated or provided. For instance, actuator 34 maycause or allow a pyrotechnic or chemical reaction when actuated,generating or providing the required inflation pressure to inflatesealing device 20. In one embodiment, actuator 34 exposes an oxidizingagent to a gaseous fuel within pipeline 10 when actuator 34 is actuated,causing a chemical reaction that generates the required inflationpressure to inflate sealing device 20.

Actuator 34 may be coupled to sealing device 20, or actuator 34 may beotherwise positioned in order to cause a sufficient inflation pressureto inflate sealing device 20. In one embodiment, actuator 34 iselectronically coupled to one or more components of sealing device 20and/or the leak sealing system (e.g., sensor assembly 26, control module50, I/O device 28, etc.), receiving signals or commands to trigger oractuate actuator 34. In one embodiment, actuator 34 is configured toreceive wireless signals or commands to trigger or actuate actuator 34,such as through a wireless receiver coupled to sealing device 20. Insome embodiments, actuator 34 may be physically triggered or actuated byone or more adjacent components of sealing device 20 and/or the leaksealing system, such as tether 32 described in further detail below.

Still referring to FIGS. 2 and 3, sealing device 20 includes bag 22(e.g., inflatable envelope, cushion, inflatable bag, etc.) which isconfigured to expand rapidly (e.g., inflate) in response to theinflation pressure. In some embodiments, bag 22 is sized and shaped tofit interior wall 16, or to otherwise match one or more dimensions ofpipeline 10 in order to fit snugly against the perimeter of interiorwall 16 when sealing device 20 has been inflated. Bag 22 is configuredto at least partially seal a leak within pipeline 10. In otherembodiments, bag 22 is sized and shaped to fit and properly seal leak 18or another type of leak typically found within pipeline 10. In oneembodiment, bag 22 is made from a stretchable fabric, but in otherembodiments, bag 22 may be made from another material suitable for theparticular application of bag 22 and/or sealing device 20. In oneembodiment, sealing device 20 includes a secondary inflatable bag (notshown) configured to selectively inflate in order to inhibit a movementof sealing device 20 or one or more of its components (e.g., bag 22,structure 24, etc.).

Sealing device 20 may also include structure 24 (e.g., mechanicalelement, mechanical structure, internal structure, internal frame, etc.)coupled to bag 22. In one embodiment, structure 24 is made from metal oran otherwise rigid material to provide a frame (e.g., skeleton,framework, form) for sealing device 20. Structure 24 may be positionedon the inside of bag 22 (as shown in the illustrated embodiment of FIGS.2 and 3), on the outside of bag 22, or in some embodiments is partiallylocated within bag 22. Structure 24 is configured to deploy when sealingdevice 20 is inflated (i.e., in response to the inflation of sealingdevice 20), pushing against interior wall 16 and/or bag 22 (depending onwhether structure 24 is positioned inside or outside of bag 22).Structure 24 applies a pressure (e.g., mechanical pressure) to bag 22and/or interior wall 16 in order to substantially cover or seal leak 18,limiting the release of fluid from pipeline 10. According to theillustrated embodiment of FIGS. 2 and 3, when actuator 34 is actuated togenerate an inflation pressure, the inflation pressure pushes structure24 outwardly from an approximate center of sealing device 20, towardinterior wall 16. As structure 24 expands outwardly, the inflationpressure forces structure 24 and bag 22 against interior wall 16,generating a wall pressure or force acting on or against interior wall16.

The inflation pressure may be controlled to limit the wall pressure,including to limit an impulse pressure (i.e. the dynamic or totalpressure applied to interior wall 16) and to limit a static pressure(i.e., the pressure applied at a specific point on interior wall 16)acting on interior wall 16. The inflation pressure, and therefore thewall pressure, may be controlled so that interior wall 16 is notcompromised or damaged by the inflation pressure and/or wall pressure.The inflation pressure may be controlled by structure 24 and/or bag 22.For instance, in one embodiment, bag 22 is staged (i.e., having morethan one stage of inflation) to apply more than one pressure or force,so that the inflation pressure or wall pressure applied by sealingdevice 20 and/or the staged airbag may be controlled to depend on themagnitude or severity of the leak. In another embodiment, bag 22includes breakable elements (not shown), or an at least partiallybreakable element, to reduce the wall pressure (e.g., impulsive load)applied to interior wall 16 as may be necessary or suitable for theparticular application of sealing device 20 and/or the conditions ofpipeline 10. For example, such breakable elements may comprise fibersattached to multiple sites on the surface of bag 22, either extendingfrom site to site inside bag 22, or along its surface. The length andstrength of the fibers can be selected to govern their breakage (andhence braking of the bag expansion) during the expansion of bag 22. Inone embodiment, structure 24 is internal to a pressure containmentportion (e.g., staged airbag, inflatable elements, etc.) of sealingdevice 20. In one embodiment, structure 24 is configured to “lock”(e.g., maintain a specific shape or formation) when sealing device 20 isinflated in order to hold sealing device 20 in place or to provideadditional strength or wall pressure for sealing device 20. In anotherembodiment, structure 24 is configured to resist inflation of sealingdevice 20, such as to reduce a force applied by sealing device 20 towall 16 of pipeline 10.

In one embodiment, structure 24 has an approximately cylindrical (e.g.,substantially cylindrical) shape when sealing device 20 is inflated (asshown in FIG. 3), with support bag 22 forming an approximatelycylindrical shape around structure 24. In this embodiment, structure 24and bag 22 may maintain an approximately (i.e., substantially)cylindrical shape before and after sealing device 20 has been inflated.In one embodiment, sealing device 20 (structure 24 and bag 22) has asubstantially toroidal shape, having a shape similar to a toroidalcylinder when sealing device 20 is in the inflated state (similar to theshape of FIG. 3). In this embodiment, fluid is able to flow through anopen center (e.g., opening 38 shown in FIG. 3) of sealing device 20after sealing device 20 has inflated, maintaining a fluid flow throughpipeline 10 in spite of the presence of sealing device 20. In otherembodiments, structure 24 and/or bag 22 may be sized and/or shapedaccording to one or more dimensions of pipeline 10. Structure 24 mayhave an approximately cylindrical shape before and/or after sealingdevice 20 has been inflated, and bag 22 may have an approximatelycylindrical shape before and/or after sealing device 20 has beeninflated. In other embodiments, structure 24 and bag 22 may have anon-cylindrical shape before and after sealing device 20 is inflated. Instill other embodiments, structure 24 and bag 22 may be of another shapeas may be suitable for the particular application of sealing device 20,including having shapes that are dissimilar from each other.

In some embodiments, structure 24 is a single piece configured to applypressure to bag 22 and/or interior wall 16 when sealing device 20 isinflated. In other embodiments, structure 24 includes two or more piecesor components configured to join together or otherwise couple to eachother before, during, or after sealing device 20 has been inflated. Instill other embodiments, structure 24 includes two or more pieces orcomponents that remain de-coupled to apply pressure at multiple pointson bag 22 and/or interior wall 16, as may be suitable for the particularapplication of sealing device 20. In one embodiment, structure 24 isconfigured to deploy into a static configuration to maintain or controla shape of sealing device 20. In this embodiment, the staticconfiguration may be selected to maintain a force applied by sealingdevice 20 to wall 16 of pipeline 10. Structure 24 may be deployed by ascissor action or another type of extension that is actuated by theinflation pressure or when the inflation pressure is generated (i.e.,the inflation pressure can be used to force deployment of structure 24).In one embodiment, structure 24 is attached to bag 22, and is deployedby forces from bag 22 as it inflates. In other embodiments, structure 24is explosively deployed by a separate energy release than that used toinflate bag 22, although both energy releases may be triggered inresponse to a common signal. In one embodiment, deployment of structure24 is configured to control inflation of sealing device 20. Whetherhaving a single piece or more than one component, structure 24 isconfigured to apply pressure to bag 22 and/or interior wall 16 in orderto cover and/or seal the leak.

According to the illustrated embodiment of FIGS. 2 and 3, actuator 34includes tether 32 (e.g., fixed-length tether). In this embodiment,tether 32 is coupled on a first end to actuator 34 (directly or byanother component of sealing device 20), and coupled on a second end toa reference point such as a stationary attachment point (not shown). Insome embodiments, tether 32 has a fixed tether length. The fixed tetherlength may be used to approximate the distance traveled by sealingdevice 20 through pipeline 10 in order to determine when sealing device20 reaches a leak location. The fixed tether length may also be selectedor cut to approximate the distance from the stationary attachment pointto the leak location. When sealing device 20 reaches the leak location,tether 32 may be fully extended or taut such that tether 32 breaks orfails, applying a force that triggers actuator 34, or otherwise causingactuator 34 to trigger such that sealing device 20 is inflated to sealthe leak.

The leak sealing system for pipeline 10 also includes sensor assembly26. Sensor assembly 26 is configured to monitor one or more conditions(i.e., pipeline condition(s)) related to sealing device 20, pipeline 10,and/or any other conditions relevant to the leak sealing system or itscomponents (e.g., flow velocity within pipeline 10, velocity of sealingdevice, dimensions of pipeline 10, etc.). In the illustrated embodimentof FIGS. 2 and 3, sensor assembly 26 is coupled to sealing device 20,but in other embodiments sensor assembly 26 may be otherwise located orpositioned within pipeline 10, such as coupled to interior wall 16 orpositioned within block valve 12, in order to monitor the pipelineconditions. Sensor assembly 26 is configured to monitor the pipelineconditions and send one or more signals representing the pipelineconditions to one or more other components of the leak sealing system.

In one embodiment, sensor assembly 26 is configured to electronicallycommunicate with control module 50, sending one or more signalsrepresenting the pipeline conditions to control module 50. Controlmodule 50 is configured to receive the signals and to create a responsebased on the signals. In one embodiment, control module 50 is programmedto use or interpret the signals to determine (i.e., calculate) otherimportant characteristics or conditions of the leak sealing system, suchas the leak location, the size and shape of the leak (e.g., the holecausing the leak), the position of sealing device 20 (i.e., sealingdevice location), or any other characteristics or conditions of the leaksealing system. Control module 50 may also be configured to send aresponse (e.g., signals, commands, etc.) to other components of the leaksealing system. For instance, in one embodiment control module 50 isprogrammed to determine the leak location and the sealing devicelocation, and to cause sealing device 20 to inflate based on the leaklocation and the sealing device location. In this embodiment, controlmodule 50 is configured to send a signal or command to actuator 34 togenerate the inflation pressure. Control module 50 may be programmed tosend one or more signals to trigger actuator 34 when sealing device 20is at or near the leak location (e.g., the leak location isapproximately equal to the sealing device location), causing sealingdevice 20 to inflate in order to seal the leak.

In the illustrated embodiment of FIGS. 2 and 3, sealing device 20includes I/O device 28 (input/output device) coupled to sealing device20. I/O device 28 may be electronically connected to sensor assembly 26and to control module 50. I/O device 28 may relay signals or commandsbetween sensor assembly 26 and control module 50. In one embodiment,sensor assembly 26 is configured to send one or more signalsrepresenting the pipeline conditions to I/O device 28, with I/O device28 sending the signals or other data to control module 50. I/O device 28may be further configured to receive signals, commands, or data fromcontrol module 50, and to send signals or commands to other componentsof sealing device 20 (e.g., actuator 34) and/or the leak sealing system.For instance, control module 50 may interpret the pipeline conditions todetermine a leak location and the sealing device location, sending acommand through I/O device 28 to actuator 34 when sealing device 20 isnear the leak location, inflating sealing device 20 to seal the leak. Inan embodiment, I/O device 28 is used to “arm” actuator 34 (e.g., onremote determination of a leak, on the dispatch of sealing device 20,etc.), in effect authorizing its activation, but leaving the actualdecision and timing of the activation up to onboard sensors (e.g., upona local determination of sealing device 20's proximity to the leak).

In at least one embodiment, sensor assembly 26 is programmed tointerpret the pipeline conditions, and configured to send one or moresignals or commands to at least one other component of sealing device 20and/or the leak sealing system based on the pipeline conditions. Forinstance, sensor assembly 26 may interpret the pipeline conditions tocalculate or determine the leak location and the sealing devicelocation, sending a signal or command to actuator 34 when sealing device20 is near (e.g., at or just upstream of) the leak location, inflatingsealing device 20 and sealing the leak.

In one embodiment, sensor assembly 26 includes one or more positionsensors (i.e., sealing device position sensors) configured to monitor aposition of sealing device 20 (e.g., position relative to pipeline 10,position relative to the leak, etc.). In some embodiments, sensorassembly 26 is configured to send one or more signals representing theposition of sealing device 20 to control module 50, either directly orby way of I/O device 28. Control module 50 may interpret the signalsreceived from sensor assembly 26 to monitor the sealing device location.In some embodiments, control module 50 is programmed to cause sealingdevice 20 to inflate based on the sealing device location. For instance,control module 50 may send a signal or command to actuator 34, eitherdirectly or through I/O device 28, when the sealing device location isapproximately equal to the leak location (i.e., sealing device 20 is ator near leak 18), inflating sealing device 20 to seal leak 18. Inanother embodiment, sensor assembly 26 is configured to send a signal orcommand directly to actuator 34, causing sealing device 20 to inflatebased on the sealing device location.

Sensor assembly 26 may also include one or more fluid sensors (e.g.,flow sensors, flow meters, flow loggers, velocimeters, etc.) configuredto monitor a fluid flow within pipeline 10. In this embodiment, the flowsensors are coupled to sealing device 20 and configured to monitor afluid flow (e.g., flow velocity, volumetric flow rate, etc.) in the areaof sealing device 20. By monitoring the fluid flow, the flow sensors(and therefore sensor assembly 26) may be configured to detect thepresence of a leak within pipeline 10. In one embodiment, flow sensors14 are positioned at intervals within pipeline 10 in order to identify aleak or a leak location. In this embodiment, fluid sensors (which may besimilar to flow sensors 14) are included as part of sensor assembly 26and coupled to sealing device 20. The flow sensors of sensor assembly 26are configured to monitor the fluid flow or fluid conditions in the areaof sealing device 20 in order to identify or determine when sealingdevice 20 is at or near the leak location.

In one embodiment, sensor assembly 26 is configured to send one or moresignals representing the fluid flow at or near sensor assembly 26 tocontrol module 50, either directly or through I/O device 28. Controlmodule 50 is configured to interpret the signals to identify a potentialleak and/or the leak location. Control module 50 may be programmed tosend a signal or command to actuator 34 when sealing device 20 is at ornear the leak location, causing actuator 34 to inflate sealing device20. In one embodiment, sensor assembly 26 is configured to interpret themonitored fluid flow to determine the leak location. Sensor assembly 26may be configured to send one or more signals representing the leaklocation to control module 50, or to send a signal or command toactuator 34 when sealing device 20 is at or near the leak location,causing actuator 34 to inflate sealing device 20 in order to coverand/or seal leak 18. For instance, sensor assembly 26 may be configuredto detect a flow disturbance (e.g., a change in volumetric flow rate orfluid flow velocity at or near sensor assembly 26), sending one or moresignals to actuator 34 when a flow disturbance is detected near sensorassembly 26 (and thus sealing device 20), causing actuator 34 to inflatesealing device 20.

Sensor assembly 26 may also include one or more light sensors (e.g.,radiometric sensors, photometric sensors, etc.) configured to detect alight (e.g., a light source, a light source gradient) near sensorassembly 26. The light sensors may be coupled to sealing device 20 aspart of sensor assembly 26 in order to determine whether a leak ispresent at or near sealing device 20. For instance, if a leak or ruptureis present within pipeline 10, a greater amount of ambient light mayenter pipeline 10 through the leak or rupture. The light sensors ofsensor assembly 26 are configured to monitor or detect this ambientlight to determine a leak location.

In one embodiment, sensor assembly 26 is configured to send one or moresignals representing the amount of light received or detected by sensorassembly 26 to control module 50. In this embodiment, control module 50is programmed to determine whether a leak condition is present based onthe signals received from sensor assembly 26. In some embodiments,control module 50 compares the amount of ambient light detected orreceived by sensor assembly 26 to a steady state light level (i.e., asteady state illumination) for when pipeline 10 is substantiallyleak-free. The steady state light level may be manually programmed orentered into control module 50, or control module 50 may be programmedto calculate or estimate the steady state light level based on theparticular conditions of pipeline 10. If the ambient light detected orreceived by sensor assembly 26 is greater than the steady state lightlevel, control module 50 may be programmed to send a signal or commandto actuator 34, causing actuator 34 to inflate sealing device 20 to sealthe leak. In another embodiment, sensor assembly 26 is configured tointerpret the light received or detected by sensor assembly 26 todetermine whether a leak is present at or near sensor assembly 26. Inthis embodiment, sensor assembly 26 may send a signal or command toactuator 34 to inflate sealing device 20 and seal a potential leak.Sealing device 20 is configured to cover and/or seal the leak wheninflated, limiting the release of fluid from pipeline 10.

Sensor assembly 26 may also include one or more radio frequency (RF)sensors configured to detect a radio frequency signal or field. Whenpipeline 10 is structurally sound (i.e., having no leaks or ruptures),an RF field may not be present within pipeline 10, or pipeline 10 maycontain an RF field having a relatively low intensity. However, when aleak occurs within pipeline 10, an ambient RF signal (e.g., from localradio, TV, or cellular phone systems) may enter pipeline 10 so that anRF field (e.g., ambient RF field) having a relatively higher intensityis present within pipeline 10. The RF sensors of sensor assembly 26 areconfigured to monitor the RF field (e.g., the presence and/or intensityof the RF field). In one embodiment, sensor assembly 26 is coupled tosealing device 20 and the RF sensors are configured to detect the RFfield at or near sealing device 20, generating one or more signalsrepresenting the RF field at or near sealing device 20. Sensor assembly26 may be configured to send the one or more signals to control module50, or to another component of sealing device 20 and/or the leak sealingsystem. In one embodiment, control module 50 is configured to receivethe one or more signals, and is programmed to determine whether a leakcondition is present near sensor assembly 26 (and thus near sealingdevice 20) based on the one or more signals. Control module 50 may beprogrammed to compare the RF field to a steady state RF field (e.g., anRF field typically associated with a substantially leak-free orstructurally sound pipeline 10), and to determine whether a leakcondition is present near sensor assembly 26 based on the relationshipbetween the received or detected RF field and the steady state RF field.In one embodiment, a leak can be detected by generating an RF fieldwithin pipeline 10 and then detecting it by an externally located sensorassembly (e.g., sensor assembly 26). In this embodiment, the generatedRF field can be distinguished from ambient RF fields by generating itwith distinctive frequency, timing, or encoding. Control module 50 maysend a signal or command to actuator 34 to inflate sealing device 20when a leak condition is present, such as when sealing device 20 is ator near a leak location.

In another embodiment, sensor assembly 26 is configured or programmed tointerpret the RF field detected or received by sensor assembly 26 inorder to determine whether a leak condition is present at or near sensorassembly 26 (e.g., whether sensor assembly 26 is at or near a leaklocation), and to send a signal or command to actuator 34 to inflatesealing device 20 when sensor assembly 26 (and thus sealing device 20)is at or near the leak location. In order to determine whether a leakcondition is present, sensor assembly 26 may compare the RF fieldreceived or detected by sensor assembly 26 to the steady state RF field.The steady state RF field may be determined based on data entered orprogrammed (through I/O device 28 or otherwise) to control module 50 orsensor assembly 26 by an operator, or may be based on particularconditions of pipeline 10.

In some embodiments, the leak sealing system is configured such thatwhen sealing device 20 is at or near a leak location, sealing device 20is automatically (i.e., without operator or other manual intervention)inflated to seal or cover the potential leak. For instance, controlmodule 50 may be programmed to automatically send a command or signal toactuator 34 when the leak sealing system determines that a leak ispresent within pipeline 10 at or near sealing device 20, causingactuator 34 to generate the inflation pressure necessary to inflatesealing device 20. In other embodiments, the leak sealing system isconfigured to provide an alert when a leak condition is present. Forinstance, control module 50 may provide one or more audible, visual, orother sensory alerts or warnings (e.g. warning light, noise, alarm,haptic joystick, etc.), so that an operator or technician associatedwith pipeline 10 is able to perceive or sense the alert. The alert maycontinue until the operator or technician takes an appropriate orrequired action, such as inflating sealing device 20 at or near the leaklocation. In one embodiment, control module 50 is programmed orconfigured to close or actuate block valves 12 surrounding the leaklocation when a leak is detected within pipeline 10, blocking fluid flowthrough the segment or section of pipeline 10 containing the leak. Inthis embodiment, block valves 12 may remain closed until an operator ortechnician takes an appropriate or required action. For instance, theoperator may be required to remotely control sealing device 20, movingsealing device 20 to the leak location. Control module 50 may beconfigured to maintain block valves 12 in a closed position untilsealing device 20 reaches closed block valve 12, at which point controlmodule 50 may open block valve 12 so that the operator is able toremotely move sealing device 20 to the leak location, remotely inflatingsealing device 20 to cover and/or seal the leak.

Sealing device 20 may be inflated when sealing device 20 is stationaryat the leak location, or sealing device 20 may be inflated as sealingdevice 20 moves toward or past the leak location. In one embodiment, themovement of sealing device 20 is controlled (i.e., by control module 50,remote control, or otherwise) such that when a leak condition is presentwithin pipeline 10, sealing device 20 is moved to the leak location.Sealing device 20 is then stopped such that sealing device issubstantially stationary at the leak location. In this embodiment,actuator 34 may be actuated only after sealing device is substantiallystationary at or near the leak location. Sealing device 20 may be slowedor stopped at the leak location by inflation of a secondary airbag(e.g., secondary inflatable bag) to brake against wall 16, by a magneticanchor to grip wall 16, by an external tether (e.g., tether 32), or bystopping or reversing a propulsion system of sealing device 20. Theposition and/or movement of sealing device 20 may be relayed ordetermined by sensor assembly 26 and/or control module 50 in thisembodiment. In other embodiments, actuator 34 may be configured suchthat actuator 34 may only be triggered or actuated at a location justbefore sealing device 20 reaches the leak location and while sealingdevice 20 is moving, at a location just after sealing device 20 hasreached the leak location and while sealing device 20 is moving, orunder any other conditions as may be suitable for the particularapplication of sealing device 20. For instance, the timing of theactuation of actuator 34 may be selected or determined such that sealingdevice 20 is inflated to substantially cover or seal the leak.

In some embodiments, sealing device 20 is moved through pipeline 10 andto a leak site or location by rocket-type propulsion. In one embodiment,sealing device 20 includes a bi-propellant rocket having solid or liquidfuel and configured to propel sealing device 20 through pipeline 10 asmay be necessary for the leak sealing system. In another embodiment,sealing device 20 includes a mono-propellant rocket, jet, or engine(e.g., an on-board oxidizer reacting with natural gas or another gaseousfuel within pipeline 10) configured to propel sealing device 20 throughpipeline 10.

In some embodiments, sealing device 20 is configured to attach tointerior wall 16 (i.e., stick in place or stick to interior wall 16)once sealing device 20 is inflated. For instance, sealing device 20 maycomprise a magnet designed to grip wall 16. Bag 22 may be coated with asealant or adhesive in one embodiment, adhering to interior wall 16 ofpipeline 10 after sealing device 20 is inflated. The sealant or adhesivemay be contained within bag 22 when sealing device 20 is in theuninflated state, and may be released or extruded from bag 22 uponinflation of sealing device 20. The sealant or adhesive may be a glue orsome other type of material or compound configured to adhere to interiorwall 16 and substantially attach bag 22 and sealing device 20 tointerior wall 16. The sealant or adhesive may be used for inhibitingmovement of sealing device 20 or one or more of its components relativeto pipeline 10. In another embodiment, sealing device 20 includes a gelor foam, or other rigidizing substance which forms in place aftersealing device 20 has inflated. The gel or foam may be internal to bag22 (or otherwise inside sealing device 20), forming in place within bag22 after inflation to rigidize and hence maintain bag 22's shape, or tomodify the wall pressure applied by sealing device 20. The gel or foammay also be a type of adhesive extruded from bag 22 or another componentof sealing device 20 to adhere sealing device 20 and/or bag 22 tointerior wall, providing a stronger seal.

Referring now to FIG. 4, sealing device 20 is shown being moved withinpipeline 10 by pipeline inspection gauge 30 (PIG) according to oneembodiment. In this embodiment, PIG 30 is configured to move throughpipeline 10, being sized and shaped to fit pipeline 10 and to crawlalong interior wall 16. PIG 30 may be utilized to move sealing device 20as necessary within pipeline 10 as PIG 30 moves through pipeline 10. Inone embodiment, PIG 30 is positioned behind sealing device 20 andconfigured to push or move sealing device 20 to a leak location to coveror seal the leak. Sealing device 20 may also be coupled to PIG 30,moving with PIG 30 to a leak location in order to cover or seal theleak. Once sealing device 20 has been inflated, PIG 30 may be moved toanother location within pipeline 10 or removed from pipeline 10. PIG 30may be remotely controlled by an operator or technician, or mayautomatically move to a leak location when a leak is identified withinpipeline 10. In one embodiment, control module 50 is configured tocommunicate with PIG 30, sending commands or instructions to PIG 30 inorder to move PIG 30 to a desired location. PIG 30 may include locationsensor 36 configured to monitor or detect a global location of PIG 30within pipeline 10. Location sensor 36 may be configured to communicatewith control module 50, sending one or more signals representing theposition or global location of PIG 30 to control module 50. Controlmodule 50 may use or interpret signals received from PIG 30 as part ofthe leak sealing system to cover or seal one or more leaks withinpipeline 10.

Referring now to FIGS. 5 and 6, sealing device 60 is shown for the leaksealing system. Sealing device 60 is similar to sealing device 20 andmay be used to seal a leak within pipeline 10. Sealing device 60 (e.g.,tubular device, sealing device, etc.) is configured to move to the siteof a leak in pipeline 10 (e.g., leak site, leak location, etc.),applying a force to the leak such that the leak is covered or sealed(i.e., fluid is prevented or inhibited from exiting pipeline 10 throughthe leak). When sealing device 60 is deployed or actuated at or near theleak location, sealing device 60 may expand or otherwise create a forceor wall pressure that acts against interior wall 16 to cover and/or sealthe leak. In some embodiments, sealing device 60 may include an actuatorsimilar to actuator 34 for deploying sealing device 60. According to theillustrated embodiments of FIGS. 5 and 6, sealing device 60 has asubstantially tubular (i.e., cylindrical, circular) shape, includingopening 62 that runs through the center of sealing device 60. Opening 62is sized and shaped such that fluid is able to pass through sealingdevice 60 as sealing device 60 crawls or moves through pipeline 10.Fluid is also able to pass through opening 62 when sealing device 60 isactuated or deployed, preserving the fluid flow through pipeline 10 andpast the leak location. In the illustrated embodiments of FIGS. 5 and 6,sealing device 60 includes wall 66 (e.g., flexible wall, closed flexiblewall) forming a substantially tubular (e.g., toroidal) shape definingopening 62 and extending the length of sealing device 60. Wall 66 mayenclose a pressurized volume of fluid (e.g., air) having a pressure thatis less than that of the fluid within pipeline 10. In one embodiment,wall 66 expands outward and toward interior wall 16, applying a wallpressure or force to interior wall 16 as may be necessary to seal theparticular leak. Wall 66 includes inner surface 74 forming the interiorsurface of sealing device 60 and outer surface 64 forming the exteriorsurface of sealing device 60. Outer surface 64 and inner surface 74 mayeach have a tubular or cylindrical shape to match the overall shape ofsealing device 60. In one embodiment, diameter 76 of sealing device 60(i.e., the diameter of outer surface 64) may be approximately equal tothe inner diameter of pipeline 10 (i.e., diameter of interior wall 16)in order to provide an adequate seal for a leak within wall 16 ofpipeline 10. In other embodiments, sealing device 60 may be sized orshaped to fit another dimension of pipeline 10. In still otherembodiments, sealing device 60 and its components may have otherdimensions suitable for the particular application of sealing device 60and/or the leak sealing system.

In one embodiment, wall 66 is generally flexible, such that sealingdevice 60 is able to move through pipeline 10 by crawling or thrustingforward incrementally with a caterpillar-like movement or action. Inthis embodiment, wall 66 is configured to fold, bend, or otherwise flexin order to create a friction between outer surface 64 and interior wall16 of pipeline 10 sufficient to drive sealing device 60 through pipeline10. For example, sealing device 60 may impose a high friction forcebetween outer surface 64 and interior wall 16 at a front portion ofsealing device 60, while flexing rearward portions of wall 66 (e.g., viainternal structure 68) so as to move a back portion of sealing device 60forward. Sealing device 60 may then impose a high friction force betweenouter surface 64 and interior wall 16 at the back portion while flexingforward portions of wall 66 (e.g., via internal structure 68), so as tomove the front portion of sealing device 60 forwards. This process canbe cyclically repeated to achieve an inchworm-like motion throughpipeline 10. Wall 66 is also configured to stop movement of sealingdevice 60 along pipeline 10 when sealing device 60 is deployed. Inanother embodiment, sealing device 60 is configured to move along withthe fluid within pipeline 10, being driven by the fluid flow throughpipeline 10. In this embodiment, wall 66 is flexible enough that fluidflow through pipeline 10 creates shear forces on inner surface 74 and/orsealing device 60 to crawl or move sealing device 60 through pipeline10, but wall 66 is stiff enough (by itself, or aided by internalstructure 68) to maintain inner surface 74 in contact with interior wall16 and to prevent wall 66 from collapsing across the bore of pipeline10. In this embodiment, wall 66 must also be stiff enough to provide asufficient sealing force against interior wall 16 to seal a leak withinpipeline 10. The flexibility and/or stiffness of wall 66 may becontrolled by internal structure 68 (i.e., structure), which is shown inFIG. 6 and described in further detail below. In another embodiment,wall 66 undergoes annular tank-tread like motion, with inner surface 74moving forward, then reversing direction at the leading edge of wall 66,moving backwards as outer surface 64, and again reversing direction atthe trailing edge of wall 66, resuming forward motion as inner surface74. A propulsive force is provided by friction between outer surface 64and interior wall 16, and the work to induce this motion can come fromfluid shear forces acting on inner surface 74 or (as in a tank) fromdrive wheels connected to internal structure 68. In one embodiment, wall66 includes a pipeline-facing surface (e.g., outer surface 64) and afluid-facing surface (e.g., inner surface 74). In this embodiment, thepipeline-facing surface and the fluid-facing surface may be configuredto repetitively change places with one another as sealing device 60moves along pipeline 10.

Sealing device 60 may also include external structures 72 positioned onouter surface 64 and configured to control the flow and speed of sealingdevice 60 as sealing device 60 moves through pipeline 10. Externalstructures 72 may be raised from outer surface 64 in one embodiment. Inanother embodiment, external structures 72 may be made from a materialconfigured to grip interior wall 16 in order to produce a greaterfriction between outer surface 64 and interior wall 16. Externalstructures 72 may be configured to control a propulsive force of thefluid within pipeline 10 on sealing device 60. In other embodiments,external structures 72 may be otherwise configured or positioned forcontrolling the flow and speed of sealing device 60, as may be suitablefor the particular application of sealing device 60 and/or the leaksealing system.

Sealing device 60 is utilized similarly to sealing device 20 to seal oneor more leaks within pipeline 10. The embodiments and configurationsdescribed above in reference to sealing device 20 may also apply tosealing device 60. As an example, sealing device 60 may be configured tocommunicate or interact with one or more communication components (e.g.,control module 50, I/O device 28, or sensor assembly 26, etc.) of theleak sealing system in a manner similar to the communication orinteraction between sealing device 20 and the one or more communicationcomponents, and any embodiments or configurations describing anycommunications or interactions between sealing device 20 and the one ormore communication devices apply accordingly to sealing device 60.

As shown in the illustrated embodiment of FIG. 6, sealing device 60includes internal structure 68 (i.e., structure or mechanical structure)coupled to inner surface 74 of wall 66. Internal structure 68 isconfigured to control the movement of sealing device 60, moving arms 70to bend, flex, or otherwise shape wall 66 as may be suitable ornecessary for the particular application of sealing device 60. Internalstructure 68 may also control the stiffness of wall 66, moving arms 70to stiffen or flex wall 66 as may be necessary or useful for theparticular application of wall 66 and/or sealing device 60. In oneembodiment, the stiffness of wall 66 is maintained or controlled byinternal structure 68 such that the fluid flow through pipeline 10creates a shear force acting on inner surface 74 to move sealing device60 through pipeline 10, but wall 66 is stiff enough (by itself, or aidedby internal structure 68) to maintain inner surface 74 in contact withinterior wall 16 and to prevent wall 66 from collapsing across the boreof pipeline 10. In at least one embodiment, internal structure 68 iscommanded or controlled to move by an external source, such as the oneor more communication components of the leak sealing system. In oneembodiment, internal structure 68 is configured to receive signals orcommands from control module 50, and to control the movement of sealingdevice 60 based on the signals or commands received from control module50. In this embodiment, control module 50 may also be configured toreceive signals representing pipeline conditions from sensor assembly26, the signals or commands sent to internal structure 68 may be basedon those signals received from sensor assembly 26. In anotherembodiment, an operator or technician may enter an input (e.g.,information or data) to control module 50, and control module 50 maysend one or more signals or commands to internal structure 68 based onthat input. Internal structure 68 may then cause sealing device 60and/or one or more components of sealing device 60 to move according tothe operator or technician input.

In another embodiment, internal structure 68 is configured to receiveone or more signals representing pipeline conditions directly fromsensor assembly 26. In this embodiment, internal structure 68 may beconfigured to interpret the signals to determine if it is necessary oruseful for internal structure 68 to move sealing device 60 and/or one ormore components of sealing device 60 in order to fulfill a function orpurpose of the leak sealing system. Internal structure 68 may then moveor control sealing device 60 accordingly. In this embodiment, sensorassembly 26 may be coupled to sealing device 60 so that sensor assembly26 is able to monitor the conditions near sealing device 60. In otherembodiments, sensor assembly 26 may be coupled to interior wall 16 ofpipeline 10, or may be positioned in another location suitable formonitoring one or more conditions within pipeline 10.

In one embodiment, internal structure 68 controls the movement ofsealing device 60 in order to move sealing device 60 to a leak locationto seal a leak. In this embodiment, a leak is identified within pipeline10 by flow sensors 14, sensor assembly 26, or otherwise, and sealingdevice 60 is moved toward the leak location by the movement of internalstructure 68. Arms 70 of internal structure 68 are moved to interactwith wall 66 such that wall 66 is bent, flexed, or otherwise manipulatedto force sealing device 60 to crawl through pipeline 10 and toward theleak location. In one embodiment, sensor assembly 26 is coupled tosealing device 60 and is configured to monitor the pipeline conditionsto determine the precise leak location. When sealing device 60 reachesthe leak location, sealing device 60 is configured to deploy or actuateto apply a pressure to wall 16 and seal the leak.

In one embodiment, internal structure 68 receives a signal or commandindicating sealing device 60 is at or near the leak location, and inresponse applies an outward pressure to wall 66. Internal structure 68is configured to control the stiffness of wall 66 by applying a greateror lesser outward pressure to wall 66. When sealing device 60 is at ornear the leak location, arms 70 may push outward from the center ofinternal structure 68 to apply an outward force or pressure in alldirections, increasing the stiffness of wall 66. The outward forceapplied and increased stiffness of wall 66 is intended to provide a sealover the leak. Internal structure 68 is also configured to stop movementof sealing device 60 along pipeline 10 when sealing device 60 isdeployed. The outward force may also be applied to prevent the collapseof pipeline 10 across its diameter in instances where the structure ofpipeline 10 is substantially harmed by the leak. The outward force mayalso be applied by internal structure 68 to prevent internal collapse ofwall 66. In one embodiment, internal structure 68 includes plates orother accessories or components to increase the surface area over whichthe outward force is applied to wall 66, more evenly distributing thewall pressure or outward force to obtain a better seal. In oneembodiment, wall 66 is made from a material configured to provide awater-tight seal over the leak.

In one embodiment, wall 66 is made from or includes one or morenon-Newtonian materials or fluids (i.e., materials or fluids having anon-linear or non-Newtonian viscosity). The non-Newtonian materials orfluids are configured to at least partially enable movement (i.e.,motion) through pipeline 10 and to create a stiffer wall 66 to cover theleak or rupture upon deployment of sealing device 60. In otherembodiments, wall 66 may be made from or include another materialconfigured to improve the sealing properties of wall 66 and/or sealingdevice 60, or any other material suitable for the particular applicationof sealing device 60 and/or the leak sealing system.

The above described sealing devices (sealing device 60 and sealingdevice 20) may be selectively positioned and/or deployed within pipeline10. In one embodiment, at least one sealing device is positioned betweenevery block valve 12 within pipeline 10. In other embodiments, sealingdevices may be positioned at lesser intervals within pipeline 10 inorder to achieve greater coverage. The sealing devices may each have adesignated area (i.e., pipe segment(s)) within pipeline 10 in which thesealing devices move in order to detect a leak condition. Sealingdevices may be launched or moved continuously or intermittently throughtheir designated pipe segment to provide substantially continuouscoverage against leaks within pipeline 10. The sealing devices may belaunched every few minutes or in shorter or longer time intervals as maybe suitable for the particular application of the sealing devices and/orthe leak sealing system. In one embodiment, a single sealing device isconfigured to move back and forth from one end of the pipe segment tothe other end of the pipe segment until a leak is detected, at whichpoint the sealing device moves to the leak location and is actuated ordeployed to seal the leak. In another embodiment, a sealing device mayinitially be at a fixed position within pipeline 10, but is thendispatched toward a leak once a leak has been detected.

Referring now to FIG. 7, a block diagram of control module 50 is shownaccording to one embodiment. Control module 50 may be used to controlthe movement and/or operation of either of the above described sealingdevices (i.e., sealing device 20 or sealing device 60) or a similarlyconfigured sealing device. Control module 50 includes processor 52 andmemory 54. Memory 54 stores programming instructions that, when executedby processor 52, control the sealing device's movement, including thevarious components of the sealing device. Control module 50 is inelectrical communication with structure 42, sensor assembly 44, andactuator 46. As described above with respect to sealing devices 20 and60, a sealing device may include structures, sensor assemblies, andactuators. In such arrangements, control module 50 is in electricalcommunication with each of the components.

Control module 50 receives operational electrical power from powersupply 56. Power supply 56 provides power to control module 50 and allcomponents of the sealing device. Power supply 56 may be any suitablepower source, including, but not limited to, a battery, a generator, asolar power source, grid power, or a combination thereof. Inarrangements where power supply 56 includes a rechargeable battery, thebattery may be charged during operation through another power source(e.g., a generator, a solar panel, grid power, etc.) or throughinductive charging (i.e., the sealing device can move over an inductivecharger within pipeline 10 configured to charge the rechargeablebattery).

Referring now to FIG. 8, a flow chart diagram for method 800 for sealinga leak in pipeline 10 is shown according to one embodiment. Method 800may be employed by either of the above described sealing devices (i.e.,sealing device 20 and/or sealing device 60) or another sealing deviceconfigured to seal a leak within a pipeline. At 802, the sealing deviceis positioned within pipeline 10. The sealing device may be a singlesealing device positioned within pipeline 10 and configured to seal aleak anywhere within pipeline 10, or the sealing device may be one of aplurality of sealing devices and configured to seal a leak within aspecified segment or area of pipeline 10. At 804, the sealing device ismoved through pipeline 10 to a leak location. The leak location may beidentified by flow sensors 14 or manually identified by an operator ortechnician and relayed to the sealing device (i.e., by control module50), identified by one or more sensors of sensor assembly 26, oridentified by another method or component of the leak sealing systemsuch as those described above. The sealing device may be moved throughpipeline 10 by tether 32, PIG 30, or by another component or method ofthe leak sealing system. Once the sealing device reaches the leaklocation, at 806, an inflation pressure is internally generated withinthe sealing device to inflate the sealing device, substantially coveringthe leak opening and limiting the release of fluid from pipeline 10. Thesealing device may be inflated by triggering actuator 34 or by causing astructure of the sealing device to apply an outward force to seal theleak opening.

Referring now generally to FIGS. 9-13, in some embodiments, the sealingdevice and/or PIG may be embodied as or within a pipeline deviceconfigured to propel itself through the pipeline by, as also describedabove, using a portion of a fluid such as natural gas traveling withinthe pipeline. For example, according to various alternative embodiments,a pipeline device includes a combustion propulsion system configured toutilize natural gas traveling within the pipeline as a fuel, and anoxidizer from an oxidizer source. The oxidizer may comprise O₂, H₂O₂,F₂, HNO₃, or the like. The oxidizer source may be or include a storagecontainer or tank on board the pipeline device, or a remote storagecontainer that may either travel with the pipeline device or be locatedexterior to the pipeline.

The combustion of the fuel and oxidizer may power a variety ofpropulsion system types, including jet engines, propeller engines,wheels, tracks or treads, and the like. As such, the pipeline device maytravel by either engaging an inner surface of the pipeline (e.g.,through one or more wheels, tracks, or treads) or in an airborne manner.The pipeline device may be used to monitor conditions of the pipeline(e.g., to identify leaks, flow stoppages, etc.), perform maintenancetasks (e.g., seal leaks, clean interior surfaces, etc.), transportvarious materials (e.g., maintenance tools, etc.), and the like.

Referring to FIG. 9, pipeline device 116 is shown within pipeline 110according to one embodiment. Pipeline device 116 is configured to travelwithin pipeline 110 and may perform various tasks, including pipelinemonitoring and maintenance, and materials transportation. Pipelinedevice 116 is in some embodiments a self-propelled device configured touse at least a portion of fluid 118 (e.g., a gaseous fuel such asnatural gas, etc.) as a fuel in a combustion propulsion system. As such,pipeline device 116 may be able to travel relatively far distanceswithin pipeline 110 without reliance upon launching devices or thepressure of the fluid travelling within pipeline 110 to move pipelinedevice 116 along the pipeline.

As shown in FIG. 9, pipeline 110 may include one or more modules 114spaced along the length of pipeline 110. Modules 114 may be or includevarious sensors, wireless communication devices, and the like. In oneembodiment, modules 114 include sensors configured to detect pipelinedevice 116 (e.g., to record the time at which pipeline device 116 passesa particular location along the pipeline). In other embodiments, modules114 act to communicate wirelessly with pipeline device 116 and/or relaydata from pipeline device 116 to other remote devices. Modules 114 maybe situated in any proper locations along pipeline 110, and may bemounted on an exterior of pipeline 110, on interior surface 112 ofpipeline 110, or may extend partially or wholly through a sidewall ofpipeline 110.

Referring to FIG. 10, pipeline device 116 is shown in greater detailwithin pipeline 110 according to one embodiment. Pipeline device 116includes PIG 122 and accessory device 120 (e.g., a sealing device,maintenance device, etc.). According to various other embodiments,pipeline device 116 may include additional or other components. PIG 122includes housing 119 configured to house or otherwise support variouscomponents of pipeline device 116.

Referring further to FIG. 10, pipeline device 116 includes propulsionsystem 124 (e.g., a combustion propulsion system, etc.) configured topropel pipeline device 116 within pipeline 110. Propulsion system 124 isin one embodiment configured to combust fuel 118 from fuel source 136(e.g., a conduit, pipe, fuel intake, compressor, valve, etc.) withoxidizer 138 from oxidizer source 139 (e.g., a container, storage tank,etc.). Propulsion system 124 is configured to propel pipeline device 116within pipeline 110, and may be or include a variety of propulsionsystems including jet engines, propeller engines, internal combustionengines, etc., and components such as turbines, pistons, compressors,nozzles, propellers, etc. In some embodiments, propulsion system 124 iscoupled to one or more traction members, shown as wheels 130. Thetraction members may include a variety of tracks, treads, or othercomponents configured to engage inner surface 112 of pipeline 110 tomove pipeline device 116 within pipeline 110. In some embodiments, innersurface 112 of pipeline 110 may include guides, tracks, rails, or thelike, to engage with the traction members.

In some embodiments, pipeline device 116 is configured to fly (i.e.,substantially unsupported by the bottom of the pipeline) while movingthough pipeline 110. In order to guide the flight of pipeline device116, one or more guides 128 may be utilized. In one embodiment, guides128 are non-contact guides or sensors and are configured to guidepipeline device 116 through the use of light beams, lasers, orultrasonic waves. In one embodiment, guides 128 are aerodynamic surfacesconfigured to generate “ground effect” type lifting forces as pipelinedevice 116 flies near inner surface 112; the use of multiple suchaerodynamic surfaces around the periphery of pipeline device 116 can beused to maintain centered flight of pipeline device 116 within the boreof pipeline 110. Alternatively, guides 128 may be contact guidesconfigured to guide pipeline device 116 through pipeline 110 throughcontact with inner surface 112. For example, guides 128 may be wheels,brushes, whiskers, or any other similar guide suitable to guide pipelinedevice 116 through pipeline 110.

In one embodiment, oxidizer 138 (e.g., oxygen, etc.) is containedonboard pipeline device 116 in storage container 139 (e.g., a container,tank, conduit, etc.). Oxidizer 138 may be stored within storagecontainer 139 as a compressed gas, or as a liquid. In alternativeembodiments, oxidizer 138 is stored off-board pipeline device 116 in aseparate container 141. Container 141 may be tethered or otherwisecoupled to pipeline device 116, and conduit 140 may direct oxidizer 138to propulsion system 124. In yet further embodiments, storage container141 is provided outside of pipeline 110 and conduit 140 directs oxidizer138 to pipeline device 116 travelling within pipeline 110.

Referring further to FIG. 10, in some embodiments, pipeline device 116includes processing circuit 126. Processing circuit 126 is coupled topropulsion system 124 and is configured to control operation ofpropulsion system 124 based on a variety of factors. For example,processing circuit 126 may control operation of propulsion system 124based on inputs received from guides 128 and/or modules 114 (e.g., speedor location inputs, etc.). Processing circuit 126 may control the flowof fuel and/or oxidizer to propulsion system 124 to control the speed ofpipeline device 116.

Referring now to FIG. 11, propulsion system 124 is shown in greaterdetail according to one embodiment. As shown in FIG. 11, propulsionsystem 124 includes combustion chamber 132 and propulsion device 134.Fuel 118 and oxidizer 138 are directed to combustion chamber 132, whichin turn powers propulsion device 134. As noted above, propulsion devicemay include a variety of combustion propulsion devices, including jetturbines, propellers, wheels, tracks, treads, and other suitable devicesto provide ground-based or airborne travel of pipeline device 116through pipeline 110. As noted above, fuel 118 is drawn from fuel source136, which in one embodiment is a fuel conduit, or fuel intake,configured to receive fuel from within pipeline 110 and direct fuel tocombustion chamber 132. In one embodiment, fuel 118 includes naturalgas. In other embodiments, fuel 118 may include other fuels suitable forflow within pipeline 110 and for combustion in combustion propulsionsystem 124, such as methane, ethane, propane, or the like.

Referring now to FIG. 12, control system 142 for pipeline device 116 isshown according to one embodiment. Control system 142 includes accessorydevice 120, processing circuit 126, and propulsion system 124. Controlsystem 142 may further include or be in communication with input/outputdevice 144 and tracking system 146. The various components of controlsystem 142 may be located locally or remotely relative to one another,and may communicate with each other using any suitable wired or wirelesscommunications protocol.

Accessory device 120 may be or include a variety of devices such asmaintenance device 152, sensor 154, and/or storage device 152.Maintenance device 152 is configured to perform one or more maintenanceoperations within pipeline 110, include sealing leaks (e.g., similar tosealing device 20), welding cracks, removing debris, cleaning theinterior walls of pipeline 110, and the like. Sensor 154 may include avariety of sensors configured to acquire data regarding pipeline 110and/or pipeline device 116, including leaks, flow rates/stoppages, speedor location of pipeline device 116, and so on. Storage device 156 isconfigured to provide storage for various materials to be transportedwithin pipeline 110. Storage device 156 may take any suitable size andshape according to various alternative embodiments.

Accessory device 120 is configured for communication with processingcircuit 126, such that processing circuit 126 receives data fromaccessory device 120 and controls operation of accessory device 120. Forexample, should sensor 154 detect a leak by way of flow ratemeasurements, accessory device 120 may provide this data to processingcircuit 126, which in turn may direct maintenance device 152 to seal theleak (e.g., as discussed according to any of the embodiments discussedherein).

Processing circuit 126 includes processor 148 and memory 150. Processor148 may be implemented as a general-purpose processor, an applicationspecific integrated circuit (ASIC), one or more field programmable gatearrays (FPGAs), a digital-signal-processor (DSP), a group of processingcomponents, or other suitable electronic processing components. Memory150 is one or more devices (e.g., RAM, ROM, Flash Memory, hard diskstorage, etc.) for storing data and/or computer code for facilitatingthe various processes described herein. Memory 150 may be or includenon-transient volatile memory or non-volatile memory. Memory 150 mayinclude database components, object code components, script components,or any other type of information structure for supporting the variousactivities and information structures described herein. Memory 150 maybe communicably connected to processor 148 and provide computer code orinstructions to processor 148 for executing the processes describedherein.

Tracking device 146 (e.g., a tracking module) is in one embodimentconfigured to track and store data regarding the movement and operationof pipeline device 116. For example, tracking device 146 may storespeed/direction data for pipeline device 116 usable to determine alocation of pipeline device 116 (e.g., in instances when pipeline 110prevents location determination via global positioning or similarmethods). Tracking device 146 may also store data related to conditionswithin pipeline 110 (e.g., leaks, etc.). Data from tracking device 146may be downloaded or wirelessly communicated to one or more remotedevices (e.g., after removal of pipeline device 116 from pipeline 110).

Input/output device 144 can include any suitable input/output deviceenabling users or other devices to provide inputs to and receive outputsfrom pipeline device 116. Input/output device is in some embodimentsconfigured to enable a user to provide operational instructions toprocessing circuit regarding one or more tasks to be performed bypipeline device 115. For example, a user may utilize device 144 toprovide maintenance or other instructions to pipeline device 116.

Referring to FIG. 13, method 160 of moving a pipeline device through apipeline is shown according to one embodiment. A pipeline device ispositioned within a pipeline (162). For example, a pipeline device suchas pipeline device 116 may be positioned within pipeline 110. Asdetailed elsewhere herein, the pipeline device may take a variety ofshapes and sizes, and be configured to perform a variety of tasks withinthe pipeline. An oxidizer is directed to a combustion chamber of thepipeline device (164). The pipeline device includes a combustionpropulsion device including a combustion chamber. The oxidizer isprovided from an oxidizer source that may travel on-board the pipelinedevice, be tethered to the pipeline device, or be otherwise remotelylocated from the pipeline device. Fuel is directed to the combustionchamber (166). In one embodiment, fuel is directed from the interior ofthe pipeline to the combustion chamber. For example, a pipeline may beused to transport natural gas. A portion of the natural gas travellingthrough the pipeline may be directed to the combustion chamber to beused as fuel. The combustion propulsion device is operated to move thepipeline device through the pipeline (168). The propulsion device mayinclude any of a number of propulsion devices including jet engines,propeller engines, and the like, to provide airborne, wheeled, or othertypes of travel for the pipeline device through the pipeline.

The construction and arrangement of the apparatus, systems and methodsas shown in the various embodiments are illustrative only. Although onlya few embodiments have been described in detail in this disclosure, manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.). For example, some elements shown as integrallyformed may be constructed from multiple parts or elements, the positionof elements may be reversed or otherwise varied and the nature or numberof discrete elements or positions may be altered or varied. Accordingly,all such modifications are intended to be included within the scope ofthe present disclosure. The order or sequence of any process or methodsteps may be varied or re-sequenced according to alternativeembodiments. Other substitutions, modifications, changes, and omissionsmay be made in the design, operating conditions and arrangement of thedescribed embodiments without departing from the scope of the presentdisclosure.

The present disclosure contemplates methods, systems and programproducts on any machine-readable media for accomplishing variousoperations. The embodiments of the present disclosure may be implementedusing existing computer processors, or by a special purpose computerprocessor for an appropriate system, incorporated for this or anotherpurpose, or by a hardwired system. Embodiments within the scope of thepresent disclosure include program products comprising machine-readablemedia for carrying or having machine-executable instructions or datastructures stored thereon. Such machine-readable media can be anyavailable media that can be accessed by a general purpose or specialpurpose computer or other machine with a processor. By way of example,such machine-readable media can comprise RAM, ROM, EPROM, EEPROM, CD-ROMor other optical disk storage, magnetic disk storage or other magneticstorage devices, or any other medium which can be used to carry or storedesired program code in the form of machine-executable instructions ordata structures and which can be accessed by a general purpose orspecial purpose computer or other machine with a processor. Wheninformation is transferred or provided over a network or anothercommunications connection (either hardwired, wireless, or a combinationof hardwired or wireless) to a machine, the machine properly views theconnection as a machine-readable medium. Thus, any such connection isproperly termed a machine-readable medium. Combinations of the above arealso included within the scope of machine-readable media.Machine-executable instructions include, for example, instructions anddata which cause a general purpose computer, special purpose computer,or special purpose processing machines to perform a certain function orgroup of functions.

The terms “coupled,” “connected,” and the like as used herein mean thejoining of two members directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent) or moveable (e.g., removableor releasable). Such joining may be achieved with the two members or thetwo members and any additional intermediate members being integrallyformed as a single unitary body with one another or with the two membersor the two members and any additional intermediate members beingattached to one another. Such joining may be communicative, rather thanphysical.

Although the figures may show or the description may provide a specificorder of method steps, the order of the steps may differ from what isdepicted. Also two or more steps may be performed concurrently or withpartial concurrence. Such variation will depend on various factors,including software and hardware systems chosen and on designer choice.All such variations are within the scope of the disclosure. Likewise,software implementations could be accomplished with standard programmingtechniques with rule based logic and other logic to accomplish thevarious connection steps, processing steps, comparison steps anddecision steps.

What is claimed is:
 1. A method for sealing a leak in a pipeline used totransport fluid, the method comprising: positioning a sealing devicewithin the pipeline; moving the sealing device through the pipeline to aleak location; internally generating an inflation pressure to inflatethe sealing device to substantially cover a leak opening and limitrelease of the fluid from the pipeline; and wherein the sealing deviceis configured such that fluid is able to flow past the leak locationwhile the sealing device is inflated to cover the leak.
 2. The method ofclaim 1, wherein the deploying step is executed based on a sealingdevice location.
 3. The method of claim 2, further comprising:determining the sealing device location based on a fixed-length tether.4. The method of claim 3, wherein the fixed-length tether is coupled tothe sealing device.
 5. The method of claim 1, wherein the deploying stepis executed when the sealing device is proximate the leak location. 6.The method of claim 1, wherein the sealing device is configured to movealong with a fluid flow through the pipeline.
 7. The method of claim 1,further comprising: coupling the sealing device to a tether; and pullingthe tether to move the sealing device through the pipeline.
 8. Themethod of claim 1, wherein the deploying step is executed when thesealing device is moving near the leak location.
 9. The method of claim1, wherein the sealing device is moved through the pipeline by arocket-type propulsion.
 10. The method of claim 9, wherein therocket-type propulsion includes a bi-propellant rocket.
 11. The methodof claim 9, wherein the rocket-type propulsion includes amono-propellant rocket.
 12. The method of claim 11, wherein themono-propellant rocket includes an oxidizer.
 13. The method of claim 1,wherein the sealing device is sized and shaped to remain substantiallystationary after deploying the sealing device.
 14. The method of claim1, wherein the sealing device includes an adhesive for engaging with awall of the pipeline.
 15. The method of claim 1, further comprising:deploying a rigidizing substance inside the sealing device.
 16. Asealing device for sealing a leak within a pipeline for transportingfluid, the sealing device comprising: a closed flexible wall formed intoa substantially tubular shape defining an opening; and an internal framecoupled to the closed flexible wall and configured to control a movementof the closed flexible wall by applying a force to the closed flexiblewall, wherein the movement of the closed flexible wall moves the sealingdevice through the pipeline, wherein the sealing device may be deployedin order to seal the leak, and wherein the closed flexible wall enclosesa pressurized volume having a pressure less than that of the fluid. 17.The sealing device of claim 16, further comprising a guide configured toreceive a force from the fluid in order to move the sealing devicethrough the pipeline.
 18. The sealing device of claim 16, wherein theclosed flexible wall includes an outer surface and an inner surface. 19.The sealing device of claim 18, wherein the outer surface has a diameterapproximately equal to the diameter of an interior wall of the pipeline.20. The sealing device of claim 16, wherein the closed flexible wall atleast partially includes a non-Newtonian material.
 21. The sealingdevice of claim 16, wherein the internal frame is configured to stopmovement of the sealing device along the pipeline when the sealingdevice is deployed.
 22. The sealing device of claim 16, wherein theclosed flexible wall is configured to stop movement of the sealingdevice along the pipeline when the sealing device is deployed.
 23. Thesealing device of claim 16, further comprising an adhesive configured toadhere the sealing device to an interior wall of the pipeline.
 24. Thesealing device of claim 23, wherein the adhesive is configured toextrude from the sealing device when the sealing device is deployed. 25.A system for sealing a leak within a pipeline for transporting fluid,the system comprising: a sealing device, comprising: a flexible wallformed into a substantially tubular shape defining an opening; and aninternal frame coupled to the flexible wall and configured to control amovement of the flexible wall by applying a force to the flexible wall;wherein the movement of the flexible wall moves the sealing devicethrough the pipeline; and wherein the sealing device may be deployed inorder to seal the leak; a sensor assembly configured to monitor apipeline condition; and a control module configured to receive a signalfrom the sensor assembly, and to control the force applied by theinternal frame.
 26. The system of claim 25, wherein the pipelinecondition includes a flow velocity.
 27. The system of claim 25, whereinthe pipeline condition includes a volumetric flow rate.
 28. The systemof claim 25, wherein the pipeline condition includes an ambient light.29. The system of claim 25, wherein the pipeline condition includes anambient RF field.
 30. The system of claim 25, wherein the control moduleis configured to move the sealing device by controlling the forceapplied by the internal frame.
 31. The system of claim 30, wherein theinternal frame is configured to move the sealing device by controllingthe movement of the flexible wall.
 32. The system of claim 31, whereinthe control module is programmed to move the internal frame such thatthe sealing device is moved to a leak location when the leak location isidentified.
 33. The system of claim 32, wherein the control module isprogrammed to identify the leak location based on the signal receivedfrom the sensor assembly.
 34. The system of claim 32, wherein thecontrol module is programmed to deploy the sealing device when thesealing device is at the leak location.
 35. The system of claim 25,wherein the internal frame is configured to apply an outward pressure tomaintain contact of the flexible wall with an interior wall of thepipeline.